SENS EnerGenius Technical Manual
Service hotline: 1.800.742.2326
1.303.678.7500
1
Installation & Operation Manual
NRG12-20: 12-Volt, 20-Amp Battery Charger
NRG24-20: 24-Volt, 20-Amp Battery Charger
NRG22-20: 12/24-Volt, 20-Amp Battery Charger
SENS Part Number:
Document Revision:
DCN Number:
Date:
101298
E
105073
January 13, 2006
Installation or service questions?
Call SENS at 1.800.742.2326 (303.678.7500)
between 8 a.m. and 5 p.m. (Mountain Time)
Monday through Friday, or visit our website.
Copyright © Stored Energy Systems LLC 2006
1840 Industrial Circle
Longmont, CO 80501
Phone: 303.678.7500
800.742.2326
Fax: 303.678.7504
Email: [email protected]
Web: www.sens-usa.com
™
®
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Service hotline: 1.800.742.2326
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IMPORTANT SAFETY INSTRUCTIONS FOR INSTALLER AND OPERATOR
1. SAVE THESE INSTRUCTIONS.
2. DO NOT EXPOSE CHARGER TO RAIN OR SNOW.
3. Use of an attachment not recommended or sold by SENS may result in a risk of fire, electric shock,
or injury to persons.
4. ONLY TRAINED AND QUALIFIED PERSONNEL MAY INSTALL AND SERVICE THIS
UNIT.
5. Do not operate charger if it has received a sharp blow, been dropped, or otherwise damaged in any way; shut
off power at the branch circuit protectors and have the unit serviced or replaced by qualified personnel.
6. To reduce risk of electric shock, disconnect the branch circuit feeding the charger before attempting any main-
tenance or cleaning. Turning off controls will not reduce this risk.
WARNING:
RISK OF EXPLOSIVE
GASES.
A. WORKING IN THE VICINITY OF A LEAD-ACID OR NICKEL-CADMIUM BATTERY IS
DANGEROUS. STORAGE BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL
BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH
TIME BEFORE USING YOUR CHARGER, YOU READ THIS MANUAL AND FOLLOW THE
INSTRUCTIONS EXACTLY.
B. To reduce the risk battery explosion, follow these instructions and those published by the battery
manufacturer and the manufacturer of any equipment you intend to use in the vicinity of a battery. Review
cautionary markings on these products and on the engine.
A. Someone should be within range of your voice or close enough to come to your aid when you work near a
storage battery.
B. Have plenty of fresh water and soap nearby in case battery electrolyte contacts skin, clothing, or eyes.
C. Wear complete eye protection and clothing protection. Avoid touching eyes while working near a storage
battery.
D. If battery electrolyte contacts skin or clothing, wash immediately with soap and water. If electrolyte enters
eye, immediately flood the eye with running cold water for at least 10 minutes and get medical attention
immediately.
E. NEVER smoke or allow a spark or flame in vicinity of battery or engine.
F. Be extra cautious to reduce risk of dropping a metal tool onto battery. It might spark or short circuit battery
or other electrical part that may cause explosion. Using insulated tools reduces this risk, but will not
eliminate it.
G. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a storage
battery. A storage battery can produce a short circuit current high enough to weld a ring or the like to metal,
causing a severe burn.
H. Use this charger for charging LEAD-ACID or LIQUID ELECTROLYTE NICKEL-CADMIUM
batteries only. Do not use this battery charger for charging dry cells, alkaline, lithium, nickel-metal-
hydride, or sealed nickel-cadmium batteries that are commonly used with home appliances. These batteries
may burst and cause injuries to persons and damage to property.
I. NEVER charge a frozen battery.
7. PERSONAL PRECAUTIONS
SENS EnerGenius Technical Manual
Service hotline: 1.800.742.2326
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This manual contains important safety, installation and operating instructions for SENS battery charger model
NRG12-20 (configured for 12V,20A only), NRG24-20 (configured for 24V, 20A only) and NRG22-20 (field
configurable for 12V or 24V, 20A).
INSTALLATION INSTRUCTIONS
WARNING:
ONLY TRAINED AND QUALIFIED PERSONNEL
MAY INSTALL AND SERVICE THIS UNIT.
MODEL NUMBER CONFIGURATION
Model Number Breakout
NRG 22-20-
Model Output Output Input Voltage Alarm System Agency Category
Voltage Current Frequency Code Code Code
12: 12 volts 20: 20 Amps H: 120/208-240V, C: 5 Alarms L: UL, CUL Listed S: Standard
24: 24 volts 50/60 Hz R: Recognized
22: 12/24 volts R: 120/208-240V, Component
60 Hz
NOTE: Not all configurations are available on all models.
Contact the factory for confirmation.
**UL listed, CSA certified
*UL listed, CSA certified and CE marked
Mount to vertical surface of 3/4” (19 mm) plywood or other
material of equal strength and durability, using four 1/4” (6
mm) diameter mounting screws. For mounting in a high
vibration environment, use of six fasteners is recommended.
6” (150 mm) minimum
ventilation clearance
top and bottom
2” (50 mm) minimum
ventilation clearance
on both sides
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Service hotline: 1.800.742.2326
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1. PREPARING FOR USE:
A. INSTALLATION OF THE UNIT MUST COMPLY WITH LOCAL ELECTRICAL CODES
AND OTHER APPLICABLE INSTALLATION CODES.
B. INSTALLATION MUST BE MADE ACCORDING TO THE INSTALLATION
INSTRUCTIONS AND ALL APPLICABLE SAFETY REGULATIONS.
WARNING:
ONLY TRAINED AND QUALIFIED
PERSONNEL MAY INSTALL AND
SERVICE THIS UNIT.
W = 13.95”
H = 13.06”
D = 6.83”
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C. This unit is permanently connected to the AC circuit and to the battery. An external disconnect device
with a minimum of 0.12”(3 mm) pole separation must be located in the AC input to the charger.
•Do not energize the AC supply circuit until ALL wiring is connected, internal controls are properly
set, and the cover is secured. Always shut the AC supply circuit off before installing or removing any
wiring or opening the cover for any reason.
•Always observe proper polarity of the DC output leads.
•Always connect the output leads in this order: ungrounded charger output first, then ungrounded
battery terminal, then grounded charger output, and grounded battery terminal last. If the battery must
be disconnected for service, remove the output wiring in the reverse of the order given above.
Use conductors rated 90C or higher.
Input conductors must be suitable for 15A circuits.
Battery conductors must be suitable for 40A circuits. See Section 5.
Alarm and temperature sensor may use low power conductors.
Use wire routing devices to
hold alarm and temperature
sensor conductors at least
1/4” (6.3 mm) away from
power conductors
Grounding
Conductor
Neutral
115/230VAC
Temperature sensor
Alarm contacts
+Battery
-Battery
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Service hotline: 1.800.742.2326
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2. CHARGER LOCATION
Do not set a battery or any other object on top of the charger. This will obstruct the ventilation openings and
cause excessive heating. Ensure the charger is protected from blowing or dripping water.
3. GROUNDING INSTRUCTIONS
This battery charger should be connected to a grounded, metal, permanent wiring system; or an equipment
grounding conductor (earthing conductor) should be run with the circuit conductors and connected to the
equipment grounding terminal in the charger. This terminal is marked with the ground symbol. Connections to
the battery charger should comply with all local codes and ordinances.
4. NEUTRAL CONNECTION
The grounded circuit conductor (neutral) should be connected to the terminal marked “N” on the input
terminal block, TB1.
5. WIRE RATINGS
A. All conductors should be rated for use at 90º C or higher.
B. All input and output conductor sizes should be coordinated with the fault protection devices: 15A on AC
input (14 AWG typical), 40A on DC output (8 AWG typical), 1 A on Alarm terminal block (20 AWG
typical).
C. Before installation, ensure adequate battery to charger wire gauge. Wire gauge that is too small may
activate the open battery detector and the charger will shut down. The maximum allowed resistance seen
by the charger is found in TABLE 1. These figures already include an allowance for charger variations
(they are 80% of the typical trip-point) and are for the complete circuit: total of battery leads, battery's
internal resistance, and any external equipment. The total resistance seen by the charger must not exceed
the following values:
D. Be sure battery terminals are clean and properly tightened. Be careful to keep corrosion from coming in
contact with eyes.
E. Add distilled water to each cell until the electrolyte reaches the level specified by the battery
manufacturer. This helps purge excess gas from the cells. Do not over fill. For a battery without cell caps,
carefully follow the manufacturer’s recharging instructions.
F. Study all battery manufacturer’s specific precautions such as removing or not removing cell caps while
charging and recommended rates of charge.
•The recommended charge current range must include the rated output current of this charger,
which is 20 amperes.
•Set the float voltage jumper to the battery manufacturer’s recommended float charge voltage.
Incorrect charge voltage will accelerate generation of explosive gases, increasing the risk of fire or
explosion.
G. Enable the automatic boost charge mode (equalizing charge) only if recommended by the battery
manufacturer
H. Determine the voltage of the battery by referring to the engine or battery owner’s manual and make sure
that the 12V/24V select jumper is set to the correct voltage.
TABLE 1
12V 24V
Maximum Resistance 36mΩ 71mΩ
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WARNING:
NEVER CHARGE STORAGE BATTERIES AT
TEMPERATURES ABOVE OR BELOW THE LIMITS
SPECIFIED BY THE BATTERY MANUFACTURER. NEVER
ATTEMPT TO CHARGE A FROZEN BATTERY.
In the case of high resistance in the cables to the battery the charger may cycle between AC Fail and
Battery Fault LEDs (approximately every 10 seconds). Cable runs exceeding the proper length for the
cable gauge used most often cause this problem. The appropriate solution is to change the cable
gauge to properly correspond with the necessary cable length (see TABLE 2). In some cases where
the resistance is not too far above maximum, the charger may recover after some time (approximately
10 minutes) and start charging the batteries. If it is not possible to decrease the system resistance the
Battery Fault feature can be disabled. Please contact SENS at 1-800-742-2326 for further
information.
E. Refer to local electrical for additional requirements.
F. See Section 9 for Terminal Block wire ranges.
Maximum Charger to
Battery Distance (Ft.)
Recommended Charger to
Battery Distance (Ft.)
AWG mΩ/Ft. 12V 24V 12V 24V
8 0.63 24 48 7 15
6 0.40 38 77 12 24
D. To determine the appropriate cable and length, please refer to the following table:
The above lengths consider the resistance of the battery and cables only and do not take into account any
additional interconnects.
The above lengths are for operation at 25C. For high temperature installations (40C) reduce lengths by 10%.
TABLE 2
6. MOUNTING LOCATION
A. See the safety instructions for important information concerning the charger location.
B. The charger should be installed in a sheltered area, protected from rain and snow.
C. The charger should not be located where temperatures are expected to be colder than
-20º C, or hotter than +40º C for operation at rated output current.
D. Allow sufficient room for routing the fixed wiring to the charger. AC input enters the left side; DC output
and alarms exit on the right.
E. Leave clear space for ventilation all around the unit: at least 6 inches (15 cm) at the top and bottom; at
least 2 inches (5 cm) on the sides.
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Service hotline: 1.800.742.2326
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F. Charger should be mounted on a flat vertical surface so that the chassis does not warp when tightened
to the wall.
G. The charger should be mounted vertically, with the input and output terminal blocks lowermost as
shown in Figure on the following page.
H. Do not mount the charger over any heat generating equipment.
I. Minimize vibrations that the charger will be subjected to.
WARNING:
OTHER MOUNTING ORIENTATIONS INTERFERE
WITH PROPER VENTILATION AND MAY CAUSE
THE CHARGER TO OVERHEAT.
7. STATIC DISCHARGE PRECAUTIONS
The printed circuit board contains static sensitive components. Damage can occur even when static levels are too
low to produce a noticeable discharge shock. To avoid static discharge damage:
A. Handle the charger by the chassis only. Remove the cover only when access is essential for installation and
service, and replace it promptly when finished.
B. If possible, wear an approved static protection strap. If one is not available, touch one hand to the chassis
before contacting any other part of the charger.
8. MOUNTING PROCEDURES
The charger mounts to a wall or other vertical support. The mounting surface must safely support the charger’s
weight, which is 40 pounds (18 kg), and also the weight of the fixed wiring.
*ATTENTION: FOR MOUNTING IN A HIGH VIBRATION ENVIRONMENT YOU MAY USE 6
FASTENERS AS SHOWN ON PAGE 4.
Mounting on a concrete surface:
•All mounting hardware is provided by the installer.
•Use optional ¾ in. thick, 18 in. x 24 in. sheet of marine plywood (not provided) to provide a suitable
mounting surface for the charger.
•Drill four holes to secure the plywood to the wall using a minimum of four ¼ in. drive pin type expansion
anchors to secure the plywood to the wall. Secure the plywood to the wall.
•Drill four (or six*) holes using the diagram on pg. 4 for ¼ (or M6) draw nut type expansion anchors
through the plywood into the cement wall.
•Insert the four (or six*) draw nut type expansion anchors through the plywood into the cement wall.
•Mount charger to draw nut type expansion anchors with nuts and flat washers.
WARNING:
THIS CHARGER IS INTENDED FOR COMMERCIAL AND
INDUSTRIAL USE. ONLY TRAINED PERSONNEL WHO ARE
QUALIFIED TO PERFORM ELECTRICAL INSTALLATIONS
SHOULD INSTALL OR SERVICE THIS UNIT.
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Mounting on a drywall:
•Use ¾ in. thick plywood to span two vertical support members in the wall. The plywood sheet normally does
not have to be more that 2 ft. by 2 ft. square.
•Place plywood to avoid electrical wiring, plumbing, etc., concealed behind wall.
•Secure the plywood to the vertical support members using ¼ in. by 2 in. lag bolts and flat washers in a
minimum of four places.
•Mark four (or six*) holes on the plywood using the diagram on pg. 4. Drill pilot holes into the plywood to
secure the mounting bolts.
•Mount charger using four (or six*) 1/4 in. by ½ in. (or M6) lag bolts and flat washers.
Mounting on a metal surface:
•Mount charger using four (or six*) ¼-20 by 3/4 in (or M6) hex head bolts, flat washers and split lock
washers to attach the battery charger to a frame, panel or cross member in four (or six*) places. Use the
diagram on pg. 4 to place the pilot holes, if needed.
•Tighten all bolts to recommended torque of 45-50 inch pounds.
9. WIRING
A. All wiring must comply with applicable codes and local ordinances. See Section 5 for recommended gauges.
B. The charger contains a DC output fuse for internal fault protection, but this will not protect the DC
wiring from fault currents available from the battery. CONSULT NATIONAL CODES AND LOCAL
ORDINANCES TO DETERMINE IF ADDITIONAL BATTERY FAULT PROTECTION IS
NECESSARY IN YOUR INSTALLATION.
C. Connect the equipment grounding conductor (earthing) to the charger’s grounding terminal. This should
always be the first wire connected and the last wire disconnected.
D. Connect the DC output conductors to TB3. Make the connections in the order shown in Figure 2A (negative
ground) or Figure 2B (positive ground). The terminals accept 10 through 6 AWG conductors.
WARNING:
ENSURE THAT AC POWER IS DISCONNECTED AT THE
CIRCUIT BREAKER OR OTHER SAFETY DISCONNECT
BEFORE WIRING THE CHARGER.
CAUTION:
OBSERVE POLARITY. THE POSITIVE CHARGER OUTPUT
TERMINAL IS LABELED “+” AND THE NEGATIVE
TERMINAL IS LABELED “-”.
WARNING:
BE SURE TO ROUTE DC POWER WIRING AT LEAST ¼ INCH (6.3
MM) AWAY FROM AC WIRING, ALARM WIRING, AND THE
CIRCUIT BOARD.
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FIGURE 2A FIGURE 2B
E. Connect the AC line and neutral conductors at TB1. If there is an identified grounded circuit conductor
(neutral), attach it to the terminal marked N. TB1 will accept 14-6 AWG conductors.
WARNING:
BE SURE TO ROUTE ALL AC WIRING AT LEAST ¼ INCH
(6 MM) AWAY FROM DC WIRING, ALARM WIRING, AND
THE CIRCUIT BOARD.
F. If the optional alarms are used, connect the alarm wiring to their respective terminals on TB5. Route
alarm wiring through the plastic bushing below TB5, keeping the conductors at least ¼ inch (6 mm)
away from DC wiring, AC wiring, and the circuit board. The terminals accept 20-14 AWG conductors.
WARNING:
CONNECT ALARM TERMINALS ONLY TO LOW
VOLTAGE, LIMITED ENERGY (“CLASS 2”) CIRCUITS.
ALARM CIRCUITS ARE RATED 24V, 1.0A MAXIMUM.
RELAY
CONTACTS
BATTERY
FAIL
ALARM
AC
FAIL
ALARM
CHARGER
FAIL
ALARM
HIGH
BATTERY
ALARM
(HI DC)
LOW
BATTERY
ALARM
(LO DC)
COMMON TB5-1
TB5-4
TB5-7
TB5-10
TB5-13
OPEN ON
ALARM
TB5-2
TB5-5
TB5-8
TB5-11
TB5-14
CLOSE ON
ALARM
TB5-3
TB5-6
TB5-9
TB5-12
TB5-15
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G. If the optional remote temperature sensor is used:
•Remove the internal sensor at TB4, if it is present.
•Locate the remote sensor where it will accurately detect the battery temperature.
•Connect the remote sensor leads to TB4. The sensor is not polarized, so it does not matter which lead
connects to terminal #1.
•Route sensor wiring through the plastic bushing below TB5, keeping the conductors at least ¼ inch
(6 mm) away from DC wiring, AC wiring, and the circuit board.
H. Verify that all connections are secure and in the proper locations. Tighten all unused screws on the terminal
blocks to secure them against vibration.
I. Ensure all wires are routed so the cover will not pinch them.
10. INTERNAL ADJUSTMENTS
WARNING:
MAKE SURE THE AC POWER TO THE CHARGER IS SHUT
OFF WHILE MAKING THE FOLLOWING ADJUSTMENTS.
AC line voltage switch
110-120V: Use 115V position
208-240V: Use 230V position
Battery range jumper
(12V or 24V battery)
Automatic boost jumper
Use NORM setting for
fast charge. Use Off set-
ting for float charge only.
Float voltage jumper
Set according to
battery supplier’s
specifications
“Jump start” battery
initialization mode
Temporary use only-
five minutes max!
SAME FOR ALL
MODELS
SENS EnerGenius Technical Manual
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A. Set the AC voltage select switch (SW100) according to the line voltage. Use the 115V position for
nominal mains voltages between 110V and 120V. Use the 230V position for nominal mains voltages
between 208V and 240V.
B. Set the battery range jumper (JP1A) according to nominal battery voltage. Use the 12V position for 12V
batteries. Use the 24V position for 24V batteries.
C. Set the boost mode jumper (JP1B) according to whether the battery should have automatic boost
charging. If the battery manufacturer recommends boost charging (equalization) use the NORMAL
position. If not, use the OFF position.
D. Set the float voltage select jumper (JP1C) according to the battery manufacturer’s recommended 25ºC
float voltage. The settings are:
•14.30/28.60 for 10 or 20 cell Nickel Cadmium at 1.43V/cell
•13.62/27.24 for 6 or 12 cell (VRLA) lead-acid at 2.27V/cell, and for 19 cell Nickel Cadmium at
1.43V/cell
•13.50/27.00 for 6 or 12 cell (VRLA or high capacity) lead-acid at 2.25V/cell, and for 19 cell Nickel
Cadmium at 1.42V/cell
•13.31/26.62 for 6 or 12 cell (flooded) lead-acid at 2.22V/cell, and for 19 cell Nickel Cadmium at
1.40V/cell
•13.08/26.16 for 6 or 12 cell lead-acid at 2.18V/cell
•12.87/25.74 for 9 or 18 cell Nickel Cadmium at 1.43V/cell
E. Replace the cover by sliding it straight onto the charger. Ensure the cover’s locating tabs engage the slots
in the chassis. Secure the cover with its four mounting screws.
F. The JUMP position allows initial charging of Nickel Cadmium batteries, or new lead acid batteries
supplied from the manufacturer dry and discharged, from a zero charge state. To use this feature,
temporarily move JP1C from the BOOST setting to the JUMP position. Operate the charger for a short
time, just long enough to retain more than 1.5V for Pb and 1.0V for NiCd per cell. Then disconnect AC
power, remove the cover, and place JP1C back to desired boost setting. Replace the cover as described
above.
WARNING:
USE THE JUMP FEATURE ONLY WITH LIQUID
ELECTROLYTE NICKEL-CADMIUM BATTERIES, OR WITH
RECENTLY FILLED NEW LEAD ACID BATTERIES
SUPPLIED FROM THE MANUFACTURER DRY AND
DISCHARGED. FOR EXCESSIVELY DISCHARGED LEAD
ACID BATTERIES THAT HAVE ALREADY BEEN IN
SERVICE, CONSULT THE BATTERY MANUFACTURER TO
DETERMINE IF AND HOW THEY CAN BE SAFELY
RESTORED TO SERVICE.
WARNING:
NEVER LEAVE A JUMPER IN THE JUMP POSITION
DURING NORMAL OPERATION. THIS DISABLES THE
BATTERY VOLTAGE INTERLOCK, WHICH INCREASES
THE RISK OF ACCIDENTALLY OVERCHARGING 12V
BATTERIES WITH THE 24V SETTINGS.
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13
11. CHECK OUT
See OPERATOR INSTRUCTION section for LED indicator definitions:
A. Verify the status LEDs:
•AC FAIL should be ON. If not, the DC output may be open or reversed, or the battery may be
extremely discharged.
•BATT FAULT should be OFF. If it lights, check for reversed polarity of the DC wiring.
•The DC LOW (Low Battery) LED may be either on or off, depending on the battery’s state of charge.
•All other LEDs and the meter display should be off.
•If the DC HIGH LED is on, check battery voltage jumper setting.
B. Select the voltmeter function by sliding the meter switch to the “V” position.
C. Apply AC power by closing the branch circuit breaker and any other disconnect devices.
D. The meter display should light immediately after power on and display the battery voltage. The green
AC /ON LED should be lighted. If a temperature sensor is present, either internal or remote, the green
T-COMP (Temperature Compensation) LED should be lighted.
E. If the BATT FAULT LED lights when AC is applied, this indicates that the battery voltage does not agree
with the Range jumper setting. The charger is interlocked, and will not operate in this condition.
Disconnect AC power, then correct the jumper setting or battery voltage before proceeding.
F. After a short delay (typically 10 seconds or less), the charger will produce output. The voltmeter reading
should increase, indicating the battery is being charged.
G. Change the meter switch to the “A” position to read output current.
•Current should be close to 20A if the battery requires recharging. If automatic boost is enabled, the
BOOST MODE LED may light, in which case the battery will be charged until it reaches 106% of the
float voltage. If boost is disabled, the green FLOAT MODE LED should be on and the battery will
charge until it reaches the float voltage setting.
•Output current will be low if the battery is fully charged, possibly too low to read on the meter. This is
normal, provided the correct charging voltage is present. The green FLOAT MODE LED should light
when output current is below approximately 18A.
SENS EnerGenius Technical Manual
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Service hotline: 1.800.742.2326
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OPERATOR INSTRUCTIONS
WARNING:
NO OPERATOR SERVICEABLE PARTS INSIDE.
DO NOT OPEN.
COVER MUST BE IN PLACE DURING USE.
USE THIS CHARGER FOR CHARGING LEAD-ACID OR
NICKEL-CADMIUM BATTERIES ONLY.
A. ADVANCED DESIGN FEATURES
Battery Friendly:
•Float and boost voltage selectable at install per specific battery vendor recommendations.
•Remote temperature compensation for most accurate float and boost voltage control.
•Able to charge a dead battery.
•Float and Boost voltage electronically controlled with a 4-rate fast charge program. See chart below.
Temperature Compensation:
•The battery charger is temperature compensated to match the negative temperature coefficient of the bat-
tery. Thus, the output voltage will increase slightly as the temperature decreases and decrease as tem-
perature increases.
•The output voltage is clamped at 0 and +40 Degrees C to protect against extremely high or low output
voltage. See chart below.
14
Temperature vs. volts per cell lead acid
2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
-30 0 20 40 60 80
Temperature Degrees C
Float volts per cell
SB
AGM
Gel
NRG
SENS limits here to prevent damaging
high voltages at customer equipment
AUTOMATIC TEMPERATURE COMPENSATION
Maintaining charge
Battery voltage
Charger in “float mode”
Finishing charge
Transition: charger shifts to
float mode when battery
current acceptance drops
Float voltage limit
High rate taper charge
Constant current charge
Battery current acceptanceBattery current acceptance
Charger in “fast charge (boost) mode”
Current limit
Boost voltage limit
Vb
Once boost voltage is
achieved current tapers off
4-RATE CHARGING
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15
B. FRONT PANEL LED INDICATOR DEFINITIONS AND TROUBLE SHOOTING:
Fault Tolerant: The charger is protected from the following faults:
•Reverse battery connection.
•Powering up into a shorted battery.
•Powering up with the wrong voltage setting (24V charger with 12V battery)
•Powering up into an open battery (Battery not connected).
•Internal power component failures.
•Over heating (over temperature output power reduction).
•Protected against power line transients and surges.
Robust Hardened Construction:
•Shock and Vibration tested to UL 991, 2G.
•Shock and Vibration tested to UL 991, 5G option available.
•Lightning transient immunity to ANSI/IEEE C62.41 Cat. B and EN 50082-2 heavy industrial.
•Wide operating temperature range: -20 to + 40 Degrees C. Charger will operate at reduced output current
rating up to +60 Degrees C.
•Conformal coated printed wiring boards for erosion protection.
Worldwide Agency Approvals:
•UL listed, UL 1236.
•CUL listed to CSA C22.2 107.2- M89.
•CE marked for EMC directive (industrial environment) and EN 60335-2-29.
•Worldwide operating voltage and frequency ranges.
SENS EnerGenius Technical Manual
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ITEM TEXT LED Meaning Troubleshooting
1 CHGR FAIL RED Charger Fail Charger unable to provide charging current
to battery. Replace unit.
AC input voltage is too low to supply
proper current when load is applied.
Control board is damaged and should be
replaced.
2 DC HIGH RED Battery DC Voltage High Check that the battery range voltage jumper
setting agrees with battery used.
High battery alarm voltage is 17v for 12v
system and 34v for 24v system.
3 DC LOW RED Battery DC Voltage Low Check that battery range voltage jumper
setting agrees with battery used. Check for
defective battery.
Check DC load.
Low battery alarm voltage is 12v for 12v
System and 24v for 24v system
4 AC FAIL RED Input AC Missing Check AC input voltage to charger. Have
qualified installer check AC line voltage
switch setting. Setting must agree with AC
voltage at site. Check AC fuse.
5 T-COMP GREEN On if Temperature Com-
pensation Working, Off if
Temperature Compensa-
tion Option not used.
Confirm if temperature compensation is
intended to be used. Only one sensor (Local
or remote) should be connected.
6 AC/ ON GREEN AC input good Should be on in normal use.
If LED is OFF, AC FAIL should be ON.
7 FLOAT
MODE
GREEN Charger Output in Float
Mode
If the automatic boost jumper is in the OFF
location, this LED will always be on.
If the automatic boost jumper is in the
“NORM” location, this LED will come on
after the battery is nearly charged up and
will stay on.
8 BOOST
MODE
AMBER Charger Output in Boost
Mode
This LED will not be on if the automatic
boost jumper is in the OFF location, or if
the automatic boost jumper is in the
“NORM” location and the battery is nearly
fully charged up.
9 BATT FAULT RED Battery Fault-Charger
automatically disabled:
•Battery reversed.
•High resistance in charger leads (leads
too small, too long , poorly connected,
open). See Section 5 for information on
wire length and gauge.
•Battery internal open circuit.
•Battery voltage does not match charger
voltage range
SENS EnerGenius Technical Manual
Service hotline: 1.800.742.2326
1.303.678.7500
17
RELAY
CONTACTS
BATTERY
FAULT
ALARM
AC FAIL
ALARM
CHARGER
FAIL
ALARM
HIGH BATTERY
ALARM
(HI DC)
LOW BATTERY
ALARM
(LO DC)
COMMON TB5-1
COM
TB5-4
COM
TB5-7
COM
TB5-10
COM
TB5-13
COM
OPEN ON
ALARM
TB5-2
OK
TB5-5
OK
TB5-8
OK
TB5-11
OK
TB5-14
OK
CLOSE ON
ALARM
TB5-3
FAIL
Defaults to OK
with no AC
input
TB5-6
FAIL
Defaults to
Fail with no
AC input
TB5-9
FAIL
Defaults to
OK with no
AC input
TB5-12
FAIL
Defaults to OK
with no battery
TB5-15
FAIL
Defaults to fail
with no battery
C. ALARM DESCRIPTION, FIVE ALARM MODEL:
NORMAL SET UP:
1. Elect the voltmeter function by sliding the meter switch to the “V” position.
2. Apply AC power by closing the branch circuit breaker and any other disconnect devices.
3. The meter display should light immediately after power on and display the battery voltage. The green
AC/ ON LED should be lighted. If a temperature sensor is present, either internal or remote, the green
T-COMP (Temperature Compensation) LED should be lighted.
4. After a short delay (typically 10 seconds or less), the charger will produce output. The voltmeter reading should
increase, indicating the battery is being charged.
5. Change the meter switch to the “A” position to read output current.
•Current should be close to 20A if the battery requires recharging. If automatic boost is enabled, the BOOST
MODE LED may light, in which case the battery will be charged until it reaches 106% of the float voltage. If
boost is disabled, the green FLOAT MODE LED should be on and the battery will charge until it reaches the
float voltage setting.
•Output current will be low if the battery is fully charged, possibly too low to read on the meter. This is normal,
provided the correct charging voltage is present. The green FLOAT MODE LED should light up when output
current is below approximately 18A.
PN: 101294 REV: C Copyright © Stored Energy Systems LLC 2006
Verify that charger
AC input switch
matches AC
supply BEFORE
energizing
charger.
CAUTION:
Applying 208/240
volts when
charger is in 115-
volt position will
blow charger
input fuse.
Thermistor activates local
temperature
compensation (TC.)
Connect optional remote
sensor here in place of
thermistor. Remove
thermistor if you wish to
disable TC
Select position closest to
the battery mfgr’s
recommended float
voltage. CAUTION:
Failure to use the proper
setting will result in poor
battery performance and
short battery life
If your c
harger is
equipped with the
optional12/24-volt
select feature, place
jumper in the voltage
of your system
battery
Enable/disable
automatic fast
charge system
CAUTION
:
Read manual
before using this
position.
AC Input
Selector
Switch
Output
Adjustments
STOP!
Verify that all settings shown below are correct before
energizing charger. CAUTION: Correct settings are essential
to ensure proper battery performance and long battery life.
Before installation, ensure adequate battery to charger wire
gauge. Wire gauge that is too small may activate the open
battery detector and the charger will shut down:
Recommended Charger to Battery
Distance (Ft.)
AWG 12V/10A 24V/10A 12V/20A
24V/20A
10 10 19 N/A N/A
8 15 30 7 15
6 24 48 12 24
For runs exceeding the above values, call SENS at 1-800-742-2326
or (303) 678-7500.
Temp comp
terminal blk
DC output
terminal
block
AC input
terminal
block
Form C alarms
terminal block
FACTORY SETTINGS
Charger is factory set for the
following settings. Change the
setting if needed for your battery
or site conditions
Input 230 VAC
Jump: DISABLED
Fast charge: ENABLED / OFF
Float voltage 14.30 28.60
13.62 27.24
13.50 27.00
13.31 26.62
13.08 26.16
12.87 25.74
Voltage range: 12-volt 24-volt
12/24 dual
JUMP
HIGH
NORM
OFF
14.30/28.60
13.62/27.24
13.50/27.00
13.31/26.62
13.08/26.16
12.87/25.74
12V
24V
NOTES:
1. LETTERING TO BE BLACK INK ON SILVER FOIL LABEL, MATERIAL RATED PER R/C (PGDQ2).
LABEL ADHESIVE PROVIDED MUST BE SUITABLE FOR USE ON ALUMINUM & RATED FOR
80 DEG C MINIMUM.
2. PSA MATERIAL IS TO BE PROVIDED WITH RELEASE LINER.
3. RADIUS CORNERS .125" MAXIMUM.
4. THIS DRAWING NOT TO SCALE.
DCN No. 105073
Drawn By: KL
Date:
1/13/2006
Approved By:
Date:
DWG Name: LABEL, INSIDE COVER, NRG10/20
PN: 808526 DWG REV.
C
BOOST
JUMPER
LOCATIONS
RANGE
FLOAT
VOL.
SEL.
ALL ADJUSTMENTS TO BE PERFORMED BY QUALIFIED PERSONNEL ONLY
SEE INSTALLATION MANUAL FOR DETAILS
With AC power
to charger OFF
1 Confirm AC safety
ground is secure.
2
Confirm that the
RANGE select jumper
setting matches the
Battery voltage. Make
no other adjustments.
10
Confirm boost sel jumper is in
correct position, see manual and item
12 below.
8
Confirm Battery Float voltage is set to match your battery
type (see manual). If battery is fully charged, the voltage
display will agree with this value at 25 C or when one leg of
temperature sensor is removed.
9
Confirm AC Sel SW setting
matches AC input voltage.
3 Connect AC input
wires to TB1.
4
Connect alarm
wires to TB5.
5 Connect output wires to
TB3. OBSERVE POLARITY.
6 Connect remote temp
sensor to TB4 if required.
7
Apply AC power to
charger. No RED LED
indicators should be on. See
manual for alarm, LED display
and jumper functions.
11
TB4
Sensor
(no polarity)
Charger will not start up if dead battery voltage is less than
75% of rated voltage. In this case momentarily short JUMP pins
using BOOST jumper to start a dead battery. Return jumper to
original position after battery voltage comes up. Do not leave
jumper in the JUMP position.
12
5.00 max
4.125
Call 1-800-742-2326
for HELP / Or visit
www.sens-usa.com
to download manual
2/27/2006 3:51 PM 808526_RevC.xls
/
